Buell X1 2002 Service Manual page 326

HOME
8. Tighten clamp around pump.
9. Press new filter (6) onto pump being careful not to dam-
age the pump assembly.
10. Install pump assembly inside fuel tank.
Fuel Pressure Regulator Replacement
1. Remove fuel pump assembly from tank.
2. See Figure 4-97. Remove two screws and washers hold-
ing fuel pressure regulator in place. Detach regulator
from pump housing.
3. Remove and discard O-rings from pump holder housing.
4. Install new O-rings in pump holder housing. Press new
regulator into place.
5. Install screws and washers. Tighten screws to 15-20 in-
lbs (1.7-2.3 Nm).
6. Install pump assembly inside fuel tank.
Low Fuel Level Sensor Replacement
1. Remove fuel pump assembly from tank.
2. See Figure 4-98. Pull apart the wire connect.
3. Remove screw holding low fuel level sensor in place.
Remove sensor from housing.
4. Install new sensor. Secure ground wire terminal under
screw. Tighten screw to 16-20 in-lbs (1.8-2.3 Nm).
5. Attach wire connect.
6. Install pump assembly inside fuel tank.
INSTALLATION
1. See Figure 4-99. Check rubber seals on electrical and
fuel outlet studs that go through tank.
2. Pump may be placed inside fuel tank by hand. Bending a
90 degree twist in the pump wiring will simplify locating
the fuel and electrical outlet holes. However, if problems
occur during installation:
a. Obtain a stiff piece of wire approximately 24 in.
(61 cm) long.
b. Attach pump electrical connector to wire.
c. Feed wire into tank through fuel filler cap hole and
out through electrical fitting hole (smaller hole) in
bottom of tank. Gently pull on wire to seat pump.
3. Install pump assembly inside tank through fuel filler cap
hole. Position pump assembly with filter facing motorcy-
cle license plate. When properly aligned, press both
studs through the holes in the bottom of tank.
4. Install new O-ring on brass adaptor nut (for fuel stud).
5. Install rubber seal, sealing washer and washer on electri-
cal outlet stud.
1 1
WARNING WARNING
Do NOT overtighten fuel fitting nuts. Overtightening fas-
teners may result in excessive compression of rubber
sealing washers and fuel leakage which could result in
death or serious injury.
6. Apply two drops of LOCTITE THREADLOCKER 243
(blue) to middle threads of the fuel and electrical outlet
studs. Use care to avoid getting threadlocker on the fuel
tank. Install nuts on studs.
4-108
7. Using a crowsfoot attachment installed at a 90˚ angle to
body of torque wrench, torque both nuts to 68-75 in-lbs
(8-9 Nm).
8. Install fuel filler cap flange assembly. See
TANK.
9. Install fuel tank. See 4.37 FUEL
6951
Fuel Pressure
Regulator
Figure 4-97. Fuel Pressure Regulator
6952
Wire Connect
Low Fuel
Level Sensor
Figure 4-98. Low Fuel Level Sensor
8293
Washer
Sealing Washer
Rubber Seals (2)
Brass Adaptor
Nut
Figure 4-99. Rubber Seals and Washers
4.37 FUEL
TANK.
Screws and
Washers (2)
Screw
Electrical Outlet Stud
Fuel Outlet Stud
O-Ring
2002 Buell X1: Fuel System